Flexible Circuit Photovoltaic Module Manufacturing
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Solution Overview
Problem
The manufacturing of photovoltaic modules is cumbersome due to the need for numerous ribbon soldering steps and bypass diode connections, especially for large modules, which complicates the process and increases costs.
Innovation Solution
A flexible circuit is electrically coupled to photovoltaic cells, using free-standing metallic articles for series connections and diode integration within a junction box, reducing the number of terminals that need to be soldered and enabling automation in the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional ribbon bus bars and multiple soldering steps are used for cell interconnections and bypass diode connections, then electrical connectivity is achieved, but manufacturing complexity and time increase significantly
Solution Approach 1:
The patent combines multiple separate functions (cell interconnection and bypass diode connection) into a single integrated flexible circuit assembly. The flexible circuit serves as both the interconnection medium between cells and the connection path to bypass diodes, eliminating the need for separate ribbon bus bars and reducing the number of soldering steps required.
Solution Approach 2:
The flexible circuit performs multiple functions simultaneously: it acts as an interconnection element between photovoltaic cells, provides connection pathways for bypass diodes, and serves as a structural support element. This multi-functionality reduces the overall number of components needed and simplifies the manufacturing process.
2Reliability
If numerous ribbon soldering steps and bypass diode connections are performed manually, then electrical connections are established, but productivity decreases and costs increase
Solution Approach 1:
The flexible circuit with bypass diodes is pre-assembled and pre-soldered as an integrated unit before being installed on the photovoltaic module. This preliminary preparation of the circuit assembly allows for automated installation and reduces the number of manual soldering steps required during final module assembly, thereby increasing productivity.
3Reliability
If multiple separate components are used for interconnections and diode connections, then electrical functionality is achieved, but ease of manufacture deteriorates
Solution Approach 1:
The patent merges the interconnection function and bypass diode connection function into a single flexible circuit assembly, which is then installed as one unit on the photovoltaic module. This integration dramatically simplifies the manufacturing process by reducing the number of separate components that need to be handled, positioned, and soldered.
Data Source
AI summary
A photovoltaic module, and method of making, is disclosed in which a flexible circuit is electrically coupled to a plurality of photovoltaic cells, where the photovoltaic cells are electrically coupled in series to form a series of cells. Each photovoltaic cell has free-standing metallic articles coupled to the top and bottom surfaces of a semiconductor substrate. A cell interconnection element of each photovoltaic cell is electrically coupled to a free-standing metallic article of an adjacent photovoltaic cell, where the interconnection elements of the initial and final cells in the series serve as contact ends for the series of cells. Contact tabs of the flexible circuit are electrically coupled to the contact ends of the series of cells, and a junction box is electrically coupled to a junction box contact region of the flexible circuit.